Scaffold plank with end connector and method of making the same

ABSTRACT

A scaffold plank assembly for engagement to a scaffolding frame. The scaffold plank assembly comprises an elongate, non-metal plank which defines opposed first and second ends and at least one interior cavity. Attached to respective ones of the opposed ends of the plank is a pair of end connectors. The end connectors each comprise a main body, and at least two arms which are attached to the main body. Attached to and extending from the main body is at least one attachment finger which is extensible into the interior cavity of the plank. The main body also includes at least two notches formed therein which are sized and configured to receive respective ones of the arms of another end connector in a nesting fashion. Additionally, disposed within the attachment finger of the end connector is an aperture which may be coaxially aligned with a pair of apertures disposed within the plank when the attachment finger is fully advanced into the interior cavity thereof. These coaxially aligned apertures are adapted to receive an elongate pin which, when advanced through the apertures and secured to the plank, maintains the end connector in firm engagement to the plank. The plank itself may further be provided with a non-slip texture which is formed directly within the outer, top surface of the top wall thereof.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application claims priority to U.S. Provisional PatentApplication Ser. No. 60/804,162 entitled SCAFFOLD PLANK WITH ENDCONNECTOR AND METHOD OF MAKING THE SAME filed Jun. 7, 2006.

STATEMENT RE: FEDERALLY SPONSORED RESEARCH/DEVELOPMENT

Not Applicable

BACKGROUND OF THE INVENTION

The present invention relates generally to scaffolding systems, and moreparticularly to a scaffold plank fabricated from a plastic material andoptionally including end connectors which are configured to facilitatethe firm engagement of the plank to a support frame structure.

As is well known in the building industry, scaffolding is virtuallyalways employed during various facets of exterior and/or interiorbuilding construction or refurbishment. Known scaffolding systemstypically comprise steel support frame structures which are selectivelyengageable to each other in a stacked fashion for achieving a desiredoverall height. In addition to the support frame structures, thescaffolding system includes a multiplicity of elongate scaffold planks,each of which is horizontally extensible between a respective pair ofthe support frame structures. The prior art scaffold planks are mosttypically fabricated from wood. Indeed, the use of wood for the priorart scaffold planks has been a long standing tradition in the buildingindustry

Though wood scaffold planks have been and continue to be generallysuitable for use in scaffolding systems, the use of wood for thescaffolding planks gives rise to certain shortcomings and deficiencieswhich detract from their overall utility. More particularly, scaffoldplanks fabricated from wood are susceptible to splitting as well as todry rot. Additionally, when exteriorly used scaffolding systems aresubjected to rain or thunder storms as often occurs, the resultant watersoaking of the wood scaffold planks virtually doubles their weight ascompared to when dry, thus substantially increasing the difficulty bywhich they are moved or otherwise manipulated. Such water soaking of thewood scaffold planks also often results in the warping or twistingthereof. As will be recognized, due to their susceptibility tosplitting, dry rot and warping/twisting, the prior art wood scaffoldplanks have a reasonably limited life span and require moderatelyfrequent replacement.

Another drawback associated with the use of wood scaffold planks is thecommon occurrence of scaffold setters experiencing splinters in theirhands when working with the same. Indeed, occurrences of splinters canreach a level of severity resulting in the initiation of a workerscompensation claim. Moreover, because nails are also often used inconjunction with wood scaffold planks, workers are more susceptible tobeing injured by nails which are left there within.

A further problem associated with the use of wood scaffold planks is therelatively high cost thereof attributable to diminishing supplies oflumber. Indeed, ongoing extensive worldwide deforestation and therelated environmental and ecological problems has, in addition toresulting in increases in the price of lumber, stimulated a movement toadopt lumber alternatives for purposes of contributing to theconservation and restoration of forests. These diminishing supplies oflumber also frequently give rise to delays in the delivery of lumber rawmaterial to those mills which manufacture wood scaffold planks, thusresulting in periodic problems in meeting the supply demands of thebuilding industry. Though metal (e.g., aluminum) scaffold planks havebeen developed in the prior art as an alternative to wood planks, suchaluminum planks are extremely costly. Additionally, both the wood andaluminum scaffold planks of currently known scaffolding systems lackconnectors which are suited to allow the plank to be quickly and easilyengaged to a support frame structure.

The present invention addresses these concerns by providing a scaffoldplank which is manufactured or fabricated from a plastic material andmay optionally be provided with end connectors which are specificallysized and configured to facilitate the quick and easy interface of theplank to a scaffolding system support frame structure. As will bediscussed below, the plastic scaffold plank of the present invention,though possessing the same level of structural integrity or rigidity asthe prior art wood scaffold planks, does not have the samesusceptibility to splitting, dry rot or warping/twisting. Additionally,the weight of the scaffold plank of the present invention is the samewhether wet or dry. The use of plastic for the scaffold planks of thepresent invention also eliminates occurrences of splinters, andsubstantially eliminates injuries potentially caused by nails lefttherein. Further, since the scaffold planks of the present invention maybe fabricated from recycled/recyclable plastic material, they addressthe need of recycling used plastic into a useful product, in addition tosatisfying the increasing desire in industry for lumber alternatives.These, and other features of the present invention will be described inmore detail below.

BRIEF SUMMARY OF THE INVENTION

In accordance with the present invention, there is provided a scaffoldplank assembly for engagement to a scaffolding frame. The scaffold plankassembly comprises an elongate, non-metal plank which defines opposedfirst and second ends and at least one interior cavity. Attached torespective ones of the opposed ends of the plank is a pair of endconnectors. The end connectors each comprise a main body defining anarcuate engagement surface, and at least two arms which are attached tothe main body. Each of the arms defines an arcuate engagement surfacewhich is substantially continuous with the body engagement surface.Attached to and extending from the main body is at least one attachmentfinger which is extensible into the interior cavity of the plank. Thebody and arm engagement surfaces are sized and configured to becooperatively engageable to the scaffolding frame.

In addition to the arcuate body engagement surface, the main bodyincludes at least two notches formed therein. The notches are sized andconfigured to receive respective ones of the arms of another endconnector in a nesting fashion, thus allowing the end connectors of twoadjacent scaffold planks to be cooperatively engaged to a common supportbar of the scaffolding frame. Additionally, disposed within theattachment finger of the end connector is an aperture which may becoaxially aligned with a pair of apertures disposed within the plankwhen the attachment finger is fully advanced into the interior cavitythereof. These coaxially aligned apertures are adapted to receive anelongate pin which, when advanced through the apertures and secured tothe plank, maintains the end connector in firm engagement to the plank.The plank itself may further be provided with a non-slip texture whichis formed directly within the outer, top surface of the top wallthereof.

BRIEF DESCRIPTION OF THE DRAWINGS

These, as well as other features of the present invention, will becomemore apparent upon reference to the drawings wherein:

FIG. 1 is a top perspective view of a scaffold plank constructed inaccordance with a first embodiment of the present invention;

FIG. 1A is a partial bottom perspective view of the scaffold plank shownin FIG. 1, illustrating the optional inclusion of a frame setting notchin the underside thereof;

FIG. 2 is a partial top perspective, cut-away view of the scaffold plankconstructed in accordance with the first embodiment of the presentinvention, illustrating its end cap as being exploded from the main bodythereof;

FIG. 2A is a front perspective view of the end cap of the scaffold plankof the first embodiment of the present invention, the rear perspectiveview of the end cap being shown in FIG. 2;

FIG. 3 is a partial top perspective, cut-away view of a scaffold plankconstructed in accordance with a second embodiment of the presentinvention;

FIG. 4 is a partial bottom perspective, cut-away view of the scaffoldplank shown in FIG. 3, illustrating its bottom cover as being explodedfrom the main body thereof;

FIG. 5 is an exploded view of a scaffold plank constructed in accordancewith a third embodiment of the present invention, and the end connectorused in conjunction therewith:

FIG. 6 is a cross-sectional view of the end connector shown in FIG. 5,further illustrating the manner in which the end connector is engaged toa segment of a support frame structure;

FIG. 7 is a top perspective view of a steel reinforcement plate of theend connector shown in FIGS. 5 and 6;

FIGS. 8 and 9 are top perspective views illustrating the manner in whichthe scaffold planks of the third embodiment including the end connectorsshown in FIGS. 5-7 are interfaced to a support frame structure;

FIG. 10 is a perspective view illustrating the manner in which scaffoldplanks of the third embodiment and the corresponding end connectors maybe interfaced to a support frame structure in side-by-side relation, andfurther illustrating an optional corner connector which may be used inconjunction with the scaffold planks of the third embodiment;

FIG. 11 is top perspective view of a scaffold plank constructed inaccordance with a fourth embodiment of the present invention having apair of end connectors cooperatively engaged to respective ones of theopposed ends thereof;

FIG. 12 is bottom perspective view of the scaffold plank shown in FIG.11;

FIG. 13 is top perspective view of the scaffold plank of the fourthembodiment similar to FIG. 11, but further illustrating one of the endconnectors as partially exploded from one end of the scaffold plank;

FIG. 14 is bottom perspective view of the scaffold plank shown in FIG.13;

FIG. 15 is top plan view of the scaffold plank of the fourth embodimentsimilar to FIG. 13, but further illustrating one of the end connectorsas fully exploded from one end of the scaffold plank;

FIG. 16 is side perspective view of one end of the scaffold plank of thefourth embodiment with the corresponding end connector removedtherefrom; and

FIG. 17 is top plan view of a connector pin which is used to secure eachof the end connectors to the scaffold plank of the fourth embodiment ofthe present invention.

DETAILED DESCRIPTION OF THE INVENTION

Referring now to the drawings wherein the showings are for purposes ofillustrating preferred embodiments of the present invention only, andnot for purposes of limiting the same, FIG. 1 perspectively illustratesa scaffold plank 10 constructed in accordance with a first embodiment ofthe present invention. The scaffold plank 10 has an elongate, generallyrectangular configuration and includes a main body 12 which definesopposed ends. Attached to the respective ones of the opposed ends of themain body 12 is a pair of identically configured end caps 14, theprecise structural attributes of which will be described in more detailbelow. In the first embodiment, the preferred height or thickness of thescaffold plank 10 is in the range of from about 1.0 inch to about 2.50inches, and is preferably about 1.50 inches. The preferred width of thescaffold plank 10 is in the range of from about 6.0 inches to about 15.0inches, and is preferably about 9.50 inches. The overall length of thescaffold plank 10 (including the main body 12 and end caps 14) isvariable. In this respect, it is contemplated that the scaffold plank 10may be provided to have an overall length of either 6 feet, 9 feet, 12feet, or 16 feet. However, those of ordinary skill in the art willrecognize that the scaffold plank 10 of the present invention may befabricated to have length, width, and/or height dimensions differingfrom those described above.

As seen in FIGS. 1 and 1A, the scaffold plank 10 may be provided withtwo pairs of pre-formed nail holes 16, with each pair of the nail holes16 being disposed within the body 12 in relative close proximity to arespective one of the end caps 14. In addition to the nail holes 16, themain body 12 of the scaffold plank may be formed to include a spacedpair of arcuately contoured, concave frame setting notches 18 in theunderside or bottom surface 20 thereof. As will be described in moredetail below, the nail holes 16 and/or frame setting notches 18, ifincluded, are preferably formed in the main body 12 via finishingoperations conducted subsequent to the fabrication of the main body 12.The nail holes 16 and/or frame setting notches 18 are used to facilitatethe engagement or interface of the scaffold plank 10 to a conventionalsteel frame support structure of a scaffolding system.

Referring now to FIGS. 2 and 2A, the main body 12 of the scaffold plank10 itself comprises a top wall 22 which defines a top surface 24, abottom wall 26 which defines the bottom surface 20, and an opposed pairof longitudinally extending sidewalls 28 which are integrally connectedto the top and bottom walls 22, 26. Integrally connected to andextending perpendicularly between the top and bottom walls 22, 26, andin particular the inner surfaces thereof, are five (5) reinforcementwebs 30. The reinforcement webs 30 extend in generally parallel relationto each other, thus defining six (6) compartments of cavities whichextend longitudinally within the interior of the main body 12. In thescaffold plank 10, the preferred thickness of the top, bottom andsidewalls 22, 26, 28 and reinforcement webs 30 is approximately 0.1875inches.

As further seen in FIG. 2, formed on the inner surface of the top wall22 and extending longitudinally therealong in spaced, generally parallelrelation to each other are seven (7) ribs 32. Similarly, formed on andextending longitudinally along the inner surface of the bottom wall 26in spaced, generally parallel relation to each other are seven (7) ribs34 which are disposed in opposed, aligned relation to respective ones ofthe ribs 32. The ribs 32, 34 extend generally perpendicularly from theinner surfaces of the top and bottom walls 22, 26, respectively. In thescaffold plank 10, the top, bottom and sidewalls 22, 26, 28 and ribs 32,34 extending within the outermost pair of cavities collectively form apair of slots which are each adapted to accommodate an elongate,rectangularly configured reinforcement bar 36. The centermost pair ofribs 32, 34, top and bottom walls 22, 26, and centermost reinforcementweb 30 also collectively define a slot which is adapted to accommodate athird reinforcement bar 36. The four remaining ribs 32 and fourremaining ribs 34 collectively define two more slots which extend withinrespective ones of those cavities disposed adjacent the outermost pairand are adapted to accommodate two additional reinforcement bars 36. Inthe scaffold plank 10, the reinforcement bars 36 are each preferablyfabricated from steel having a thickness of approximately 0.1875 inches.

In the scaffold plank 10 shown in FIG. 2, three (3) reinforcement bars36 are depicted as being disposed within respective ones of the five (5)slots extending within the interior of the main body 12. Those ofordinary skill in the art will recognize that no reinforcement bars 36need to be provided within the main body 12, and that less than three orup to five reinforcement bars 36 may be included therein. The number ofreinforcement bars 36, if any, included in the interior of the main body12 of the scaffold plank 10 is dependent upon the level of structuralintegrity or rigidity desired in relation thereto. In the scaffold plank10, each of the reinforcement bars 36 is preferably sized such that whendisposed within the interior of the main body 12 in the above-describedmanner, the opposed ends thereof do not protrude beyond respective onesof the opposed ends of the main body 12.

As indicated above, in addition to the main body 12, the scaffold plank10 includes the end caps 14 which are attached to respective ones of theopposed ends of the main body 12. As seen in FIGS. 2 and 2A, each of theend caps 14 has a generally rectangular configuration, and includes anouter surface 38 which defines a pair of beveled or concave cornerregions adjacent respective ones of the lateral sides thereof. Inaddition to the outer surface 38, each end cap 14 has an inner surface40 which includes an elongate channel 42 formed therein. The channel 42is formed within each end cap 14 for purposes of reducing the overallweight thereof. As seen in FIG. 2, the channel 42 terminates inwardly ofthe lateral sides of the end cap 14.

Formed on the inner surface 40 of each end cap 14 are a total of eight(8) rectangularly configured attachment tabs 44. The attachment tabs 44are arranged in two sets of four, with the attachment tabs 44 of eachset being disposed in spaced relation to each other along a respectiveone of the longitudinal sides of the channel 42. Additionally, theattachment tabs 44 of one set are disposed in opposed, linear alignmentwith respective ones of the attachment tabs 44 of the other set.Importantly, the attachment tabs 44 are oriented so as to be advanceableinto respective ones of the cavities defined within the main body 12 andnot interfere with any of the reinforcement webs 30 thereof. In thisrespect, the attachment tabs 44 are sized and configured such that wheneach opposed pair thereof is received into a respective one of thecavities of the main body 12, those edges of the attachment tabs 44disposed furthest from the channel 42 are in abutting contact with theinner surfaces of respective ones of the top and bottom walls 22, 26 ofthe main body 12. Those of ordinary skill in the art will recognize thatdifferent numbers of attachment tabs 44 arranged in alternative patternsare contemplated in relation to the end caps 14. In the scaffold plank10, each of the end caps 14 may be sonically welded to the main body 12,or may alternatively be attached to the main body 12 through the use offasteners such as pins, snap fit, or an adhesive. However, those ofordinary skill in the art will recognize that other methods may beemployed to facilitate the attachment of the end caps 14 to the mainbody 12. As is seen in FIG. 1, the end caps 14 are sized relative to themain body 12 such that when attached thereto, the longitudinal sides ofthe end caps 14 are substantially flush with the bottom surface 20 ofthe bottom wall 26 and top surface 24 of the top wall 22, with thelateral sides of the end caps 14 being substantially flush withrespective ones of the outer surfaces of the sidewalls 28.

Both the main body 12 and end caps 14 of the scaffold plank 10 arepreferably fabricated from a plastic material. A preferred plasticmaterial is a ten percent to fifty percent glass-filledpolypropylene/nylon blend. Such plastic material may alternativelycomprise either virgin or recycled plastic. It is contemplated that theplastic or nylon material may be filled with either glass or anothersuitable reinforcement material to increase the structuralintegrity/rigidity thereof. Those of ordinary skill in the art willfurther recognize that the main body 12 and end caps 14 need notnecessarily be fabricated from identical materials. In this respect,each of the end caps 14 could be fabricated from a metallic materialsuch as aluminum. As indicated above, each of the reinforcement bars 36is preferably fabricated from steel.

Additionally, the main body 12 of the scaffold plank 10 is preferablyfabricated via an extrusion process. If one or more reinforcement bars36 is to be included within the interior of the main body 12, it ispreferred that the plastic material used to form the main body 12 willbe extruded about the reinforcement bar(s) 36. However, those ofordinary skill in the art will recognize that the reinforcement bars 36may be inserted into the interior of the main body 12 via a separateprocedure which is conducted subsequent to the formation of the mainbody 12 via the extrusion process. The end caps 14 are preferablyfabricated through the use of an injection molding or vacuum formingprocess and, as indicated above, secured to respective ones of theopposed ends of the main body 12 subsequent to the fabrication of thesame.

Subsequent to the fabrication of the main body 12 via the extrusionprocess, it is contemplated that the nail holes 16 may be formed thereinvia a follow-up drilling operation. Additionally, the frame settingnotches 18 may be formed in the bottom surface 20 via a follow-upgrinding or machining operation. Moreover, the top surface 24 of the topwall 22 may be subjected to a grinding or machining operation forpurposes of applying a texture or roughened feature thereto. Though notshown, it is further contemplated that the cavities defined by the mainbody 12 may be filled with structural foam or some equivalent theretoprior to the attachment of the end caps 14 to the main body 12 forpurposes of increasing the structural strength or rigidity of thecompleted scaffold plank 10.

Referring now to FIGS. 3 and 4, there is depicted a scaffold plank 100constructed in accordance with a second embodiment of the presentinvention. The scaffold plank 100 also has an elongate, generallyrectangular configuration and includes a main body having a top wall 104which defines a top surface 106, an opposed pair of longitudinallyextending sidewalls 108 which are integrally connected to the top wall104, and an opposed pair of end walls 110 which are integrally connectedto the top and sidewalls 104, 108 and define respective ones of theopposed ends of the scaffold plank 100. Though the scaffold plank 100 ofthe second embodiment preferably does not include the previouslydescribed end caps 14 since the opposed ends thereof are defined by theend walls 100 of the main body 102, those of ordinary skill in the artwill recognize that such end caps 14 may be employed as an alternativeto the integrally formed end walls 100. Similar to the configuration ofthe outer surfaces 38 of the end caps 14, the end walls 110 of the mainbody 102 may be formed to include beveled corner regions adjacentrespective ones of the sidewalls 108.

As is seen in FIGS. 3 and 4, the main body 102 of the scaffold plank 100is formed to include four (4) channel members 112 which are integrallyconnected to the inner surface of the top wall 104 and extendlongitudinally therealong in spaced, generally parallel relation to eachother. The outermost pair of channel members 112 each has a generallyL-shaped configuration and, in addition to being integrally connected tothe inner surface of the top wall 104, are integrally connected to theinner surfaces of respective ones of the sidewalls 108. The central twochannel members 112 each have a generally U-shaped configuration and areintegrally connected to only the inner surface of the top wall 104. Inthe scaffold plank 100, the outermost pair of channel members 112 andinner surfaces of the top and sidewalls 104, 108 collectively define apair of slots, with another pair of slots being collectively defined bythe central two channel members 112 and inner surface of the top wall104. Each of these four (4) slots has a generally rectangularconfiguration and extends substantially along the length of the mainbody 102. Additionally, each of these slots is sized and configured toaccommodate a reinforcement bar 114 which is identically configured tothe previously described reinforcement bar 36 and preferably fabricatedfrom steel.

In addition to the channel members 112, integrally connected to andextending perpendicularly from the inner surface of the top wall 104 arethree (3) longitudinally extending primary reinforcement webs 116. Inthe scaffold plank 100, each of the primary reinforcement webs 116 isdisposed equidistantly between an adjacent pair of channel members 112and extends in generally parallel relation thereto. Integrally connectedto and extending angularly between each of the primary reinforcementwebs 116 and the channel members 112 of the corresponding pair are aplurality of secondary reinforcement webs 118 which are also integrallyconnected to the inner surface of the top wall 104 and extend generallyperpendicularly relative thereto. As is best seen in FIG. 4, the channelmembers 112 and primary and secondary reinforcement webs 116, 118 areeach sized and configured such that the distal surfaces thereof (i.e.,those surfaces disposed furthest from the inner surface of the top wall104) and are oriented inwardly from the distal edges of the sidewalls108 and end walls 110 (or end caps 14) of the main body 102. In thisrespect, the distal edges of the side and end walls 108, 110 of the mainbody 102 protrude slightly outwardly from the distal surfaces of thechannel members 112 and primary and secondary reinforcement webs 116,118 for reasons which will be described in more detail below.

In addition to the main body 102, the scaffold plank 100 of the secondembodiment may comprise a cover member 120 which also has an elongate,generally rectangular configuration and define opposed, generally planarsurfaces. In the scaffold plank 100, the cover member 120 is attached tothe main body 102 such that the inner surface of the cover member 120lies in abutting contact with the distal surfaces of the channel members112 and primary and secondary reinforcements webs 116, 118. In thisrespect, the length and width dimensions of the cover member 120 areslightly smaller than those of the main body 102 such that when theinner surface of the cover member 120 is placed in abutting contact withthe channel members 112 and primary and secondary reinforcement webs116, 118 in the aforementioned manner, the outer surface of the covermember 120 is substantially flush or continuous with distal edges of theside and end walls 108, 110 of the main body 102.

The attachment of the cover member 120 to the main body 102 ispreferably facilitated through the use of sonic welding, pins, or anadhesive. However, those of ordinary skill in the art will recognizethat other methods may be employed to facilitate the attachment of thecover member 120 to the main body 102. Since the cover member 120, whenattached to the main body 102, does not protrude beyond the side and endwalls 108, 110 of the main body 102, the overall length, width andheight dimensions of the scaffold plank 100 are governed by the mainbody 102 thereof. Though not shown, it is contemplated that a sealingstrip will be compressed between the cover member 120 and the main body102 when the cover member 120 is attached to the main body 102.

In the second embodiment, the preferred height or thickness of the mainbody 102, and hence the scaffold plank 100, is in the range of fromabout 1.0 inch to about 2.50 inches, and preferably about 1.50 inches.The preferred width of the main body 102 is in the range of from about6.0 inches to about 15.0 inches, and is preferably about 9.50 inches.The overall length of the main body 102 is variable, with it beingcontemplated that the same may be provided in lengths of either 6 feet,9 feet, 12 feet, or 16 feet.

Like the main body 12 and end caps 14 of the scaffold plank 10 of thefirst embodiment, both the main body 102 and cover member 120 of thescaffold plank 100 of the second embodiment are preferably fabricatedfrom a plastic material. As is the first embodiment, a preferred plasticmaterial is a ten percent to fifty percent glass-filledpolypropylene/nylon blend. An alternative plastic material may be eithervirgin or recycled plastic. It is contemplated that the plastic or nylonmaterial may be filled with either glass or another suitablereinforcement material to increase the structural integrity/rigiditythereof. As indicated above, each of the reinforcement bars 114 ispreferably fabricated from steel. However, the reinforcement bars 114 aswell as the above-described reinforcement bars 36 may each be fabricatedfrom a material other than steel.

In the scaffold plank 100 shown in FIGS. 3 and 4, four (4) reinforcementbars 114 are depicted as being disposed within respective ones of thefour (4) slots extending within the interior of the main body 102. Thoseof ordinary skill in the art will recognize that no reinforcement bars114 need be provided within the main body 102, and that less than four(4) reinforcement bars 114 may be included therein. The number ofreinforcement bars 114, if any, included in the interior of the mainbody 102 of the scaffold plank 100 is dependent upon the level ofstructural integrity or rigidity desired in relation thereto.Additionally, though the main body 102 is shown as including four (4)channel members 112 and three (3) primary reinforcement webs 116, thoseof ordinary skill in the art will recognize that the main body 102 maybe formed to include greater or fewer channel members 112 and/or primaryreinforcement webs 116.

As indicated above, no reinforcement bars 114 need to be provided withinthe main body 102. In this respect, it is contemplated that as analternative to the reinforcement bars 114 being included in the mainbody 102, the channel members 112 may be formed to be of a solidcross-sectional configuration as opposed to partially defining theabove-described rectangularly configured slots. In this respect, basedupon the particular plastic material used to form the main body 102, theformation of the same with the solid channel members 102 may besufficient to impart the desired amount of structural integrity/rigidityto the scaffold plank 100.

In the second embodiment, the main body 102 of the scaffold plank 100 ispreferably fabricated via an injection molding process, as is the covermember 120 thereof. If one or more reinforcement bars 114 is to beincluded within the interior of the main body 102, such reinforcementbar(s) 114 will typically be pre-positioned within the mold, with theplastic material thereafter being injection molded about the same, thusresulting in the reinforcement bars 114 being molded in place.Additionally, as seen in FIG. 3, it is contemplated that the mold may beformed to provide the top surface 106 of the top wall 104 with non-skidcharacteristics through the formation of multiple, generally circularprotuberances 122 thereon, with such protuberances 122 being arranged ingenerally parallel rows. As an alternative to being formed to includethe protuberances 122, the top surface 106 of the top wall 104 may besubjected to a follow-up grinding or machining operation subsequent tothe molding of the main body 102 for purposes of applying a texture orroughened feature thereto. The outer surface of the cover member 120 mayalso be formed to include a texture or roughened feature. Though themain body 102 and the cover member 120 are preferably fabricated via aninjection molding process, it is contemplated that either or both of themain body 102 and cover member 120 may be fabricated via a vacuumforming or extrusion process. Additionally, though not shown, it iscontemplated that the previously described nail holes 16 and/or framesetting notches 18 may be formed within the scaffold plank 100 viaprocesses/techniques similar to those previously described in relationto the scaffold plank 10 of the first embodiment.

It is contemplated in the scaffold plank 100 of the second embodiment,the cover member 120 may be formed as an integral portion of the mainbody 102 as opposed to a separate component attached thereto. In thisrespect, the main body 102 including the cover member 120 as an integralportion thereof may be formed or fabricated as a totally symmetricalcomponent or part. Both of the sides or faces of such symmetrical partcould be provided with a texture or roughened feature, with the absenceof any nail holes 16 and frame setting notches 18 allowing the same tobe positioned upon scaffolding in any orientation. If formed to includethe cover member 120 as an integral portion thereof, it is contemplatedthat the main body 102 will be molded in two identical halves defined bybisecting the side walls 108 along a common plane. These two symmetricalhalves of the main body 102 (one of which would include the integrallyformed cover member 120) would be attached to each other via sonicwelding or an adhesive to facilitate the formation of the scaffold plank100. Each of the symmetrical halves could be individually fabricated viainjection molding, rotational molding, or a vacuum forming process.

Referring now to FIG. 5, there is shown a scaffold plank 200 constructedin accordance with a third embodiment to the present invention. Thescaffold plank 200 is preferably outfitted with a pair of end connectors202 which are cooperatively engaged to respective ones of the opposedends of the scaffold plank 200. The structural and functional attributesof each end connector 202 (one of which is shown in FIG. 5 as explodedfrom the scaffold plank 200) will be described in more detail below.

As seen in FIG. 5, the scaffold plank 200 is preferably a unitarystructure which defines a generally planar, sheet-like top wall 204 anda generally planar, sheet-like bottom wall 206. The top and bottom walls204, 206 extend in spaced relation to each other along respective onesof a generally parallel pair of planes. Extending perpendicularlybetween corresponding pairs of the longitudinal edges of the top andbottom walls 204, 206 is a spaced, generally parallel pair of side walls208. Though the inner surfaces of the side walls 208 are generallyplanar, the outer surfaces thereof each include an integral upper rail210 and an integral lower rail 212 extending longitudinally therealongin spaced, generally parallel relation to each other. The upper rails210 extend along respective ones of the opposed longitudinal sides ofthe top wall 204, and are each substantially flush with the outersurface of the top wall 204. Similarly, the lower rails 212 extend alongrespective ones of the opposed longitudinal sides of the bottom wall 206and are each substantially flush with the outer surface of the bottomwall 206. As shown in FIG. 5, each of the upper and lower rails 210, 212is preferably hollow, though the same may alternatively be formed tohave solid cross-sectional configurations. Due to the inclusion of theupper and lower rails 210, 212 thereon, each side wall 208 defines anelongate slot 214, the use of which will also be discussed in moredetail below.

The scaffold plank 200 further comprises a plurality of reinforcementwalls 216 which extend perpendicularly between the inner surfaces of thetop and bottom walls 204, 206. The reinforcement walls 216 extendlongitudinally along the length of the scaffold plank 200 in spaced,generally parallel relation to each other. Though the reinforcementwalls 216 are equidistantly spaced relative to each other, the spacingbetween the outermost pair of reinforcement walls 216 and respectiveones of the side walls 208 is reduced in comparison to the spacingbetween the reinforcement walls 216. As a result, an outer pair ofcavities collectively defined by the top and bottom walls 204, 206,outermost pair of reinforcement walls 216, and side walls 208 each havea width which is less than that of multiple inner cavities which areeach collectively defined by the top and bottom walls 204, 206 and anadjacent pair of the reinforcement walls 216. As seen in FIG. 5, thescaffold plank 200 is formed to include five reinforcement walls 216. Asa result, the scaffold plank 200 includes four inner cavities and twoouter cavities which, as indicated above, are of reduced width ascompared to the inner cavities. However, those of ordinary skill in theart will recognize that the number of reinforcement walls 216 includedin the scaffold plank 200 as shown in FIG. 5 is exemplary only, in thatgreater or fewer reinforcement walls 216 may be formed to extend betweenthe top and bottom walls 204, 206. Also exemplary is the spacing betweenthe reinforcement walls 216, in that it is contemplated that thereinforcement walls 216 may be equidistantly spaced relative to eachother and to the side walls 208, thus causing all of the cavitiesdefined by the scaffold plank 200 to be of equal size.

It is contemplated that the scaffold plank 200 of the third embodimentwill be fabricated in its entirety from a non-metal material via anextrusion or injection molding process. Exemplary materials for thescaffold plank 200 include various types of plastics (e.g., glass-filledpolyethylene), fiber reinforced composites, or combinations thereof. Inthis regard, it is further contemplated that the extrusion processpreferably used to facilitate the formation of the scaffold plank 200may be carried out in a manner wherein various portions of the scaffoldplank 200 are fabricated from a fiber reinforced plastic or composite,with other portions simply being fabricated from a non-reinforcedplastic material. More particularly, depending on the level ofstructural integrity desired for the scaffold plank 200, one or more ofthe reinforcement walls 216 may be fabricated from a fiber reinforcedcomposite material, with the remainder of the scaffold plank 200 beingfabricated from a plastic material. As indicated above, the extrusionprocess preferably used to facilitate the formation of the scaffoldplank 200 may be completed such that the scaffold plank 200 is a unitarystructure, despite proscribed areas of the scaffold plank 200 beingfabricated from differing non-metallic materials. As a furthervariation, the scaffold plank 200 as shown in FIG. 5 may be fabricatedentirely from a non-reinforced plastic material, with reinforcing sheetsof a fiber reinforced composite material being applied to the outersurface of the top wall 204 and/or the outer surface of the bottom wall206 for purposes of increasing the structural integrity/rigidity of thescaffold plank 200. In the scaffold plank 200, the outer surface of thetop wall 204 and the outer surface of the bottom wall 206 are preferablyformed to have a roughened or textured feature to provide the scaffoldplank 200 with non-slip characteristics. However, those of ordinaryskill in the art will recognize that the non-skid, roughened texture maybe included on only the outer surface of the top wall 204.

Referring now to FIGS. 5-7, as indicated above, the scaffold plank 200of the third embodiment preferably includes a pair of end connectors 202cooperatively engaged to respective ones of each of the opposed endsthereof. Each end connector 202 includes an engagement portion 218having a main body 220 which defines an arcuate, generally concave bodysurface 222. The body surface 222 spans approximately ninety degrees.Formed within the main body 220 is a spaced pair of notches 224, each ofwhich has a generally V-shaped configuration defining an arcuate lowerapex. In addition to the main body 220, the engagement portion 218 ofthe end connector 202 includes a spaced, identically configured pair ofarms 226 which are integrally connected to the main body 220. Each ofthe arms 226 defines an arcuate, generally concave arm surface 228which, like the body surface 222, also spans approximately ninetydegrees. The main body 220 and arms 226 are oriented relative to eachother such that one of the notches 224 is disposed between the arms 226,with the remaining notch 224 being disposed between one arm 226 and onelateral end of the main body 220. Importantly, the main body 220 andarms 226 are oriented relative to each other such that the arms surfaces228 of the arms 226 are continuous with the body surface 222 of the mainbody 220. Thus, the arms surfaces 228 and portions of the body surface222 collectively define engagement surfaces which span, in total,approximately 180°. Each arm 226 also has a generally V-shapedconfiguration when viewed from a top perspective, with the side walls ofthe arm 26 oriented between the notches 224 being continuous with theside walls of such notches 224. One side wall of the remaining arm 226is continuous with the side wall of the notch 224 disposed between thearms 226. As seen in FIG. 5, due to the shape of the engagement portion218 of the end connector 202, the depth of the notch 224 located betweenthe arms 226 appears to be greater than that of the remaining notch 224due to the side wall of the notch 224 between the arms 226 beingcontinuous with one side wall of each of the arms 226.

In addition to the engagement portion 218, the end connector 202includes a plurality of elongate attachment fingers 230 which protrudeperpendicularly from the side of the main body 220 opposite thatincluding the body surface 222 formed therein. The fingers 230 extend inspaced, generally parallel relation to each other, and are eachpreferably hollow. As is best seen in FIG. 5, the fingers 230 are sizedand configured to be advanceable into respective ones of the cavitiesdefined by the scaffold plank 200. In this regard, since the cavities ofthe scaffold plank 200 are of differing widths as indicated above, theoutermost pair of fingers 230 of the end connector 202 are of reducedwidth as compared to the remaining fingers 230. In this regard, theoutermost pair of fingers 230 are sized and configured to be advanceableinto respective ones of the outer pair of cavities defined by thescaffold plank 200, with the remaining fingers 230 being sized andconfigured to be advanceable into respective ones of the inner cavitiesdefined by the scaffold plank 200. The advancement of the fingers 230into respective ones of the cavities is limited by the abutment of aperipheral portion of the surface of the main body 220 from which thefingers 230 extend against corresponding lateral edges of the top andbottom walls 204, 206 and side walls 208 of the scaffold plank 200, inthe manner shown in FIG. 6.

It is contemplated that the end connector 202 will be fabricated from aplastic material via an injection molding process, with the attachmentfingers 230 being integrally connected to the main body 220 of theengagement portion 218. As seen in FIGS. 6 and 7, it is furthercontemplated that the structural integrity of each end connector 202 mayoptionally be increased through the inclusion of a reinforcement plate244 therein. The reinforcement 244 is preferably fabricated from a metalmaterial (e.g., steel), and has a shape which is complimentary to thatof the main body 220, arms 226, and fingers 230. More particularly, thereinforcement plate 244 includes a plurality of reinforcement fingers246 which are sized and configured to be advanceable into the interiorsof respective ones of the attachment fingers 230. Additionally, thereinforcement plate 244 includes a pair of arcuate reinforcement arms248 which are extensible into the interiors of respective ones of thearms 226. Since the end connector 202 is preferably fabricated via aninjection molding process, it is contemplated that the reinforcementplate 244 will initially be included in the mold cavity, with theplastic material used to form the remainder of the end connector 202being injected into the mold cavity in a manner effectivelyencapsulating the reinforcement plate 244 in the manner shown in FIG. 6.

As indicated above, the cooperative engagement of each end connector 202to a respective end of the scaffold plank 200 is facilitated by theadvancement of the fingers 230 of the end connector 202 into respectiveones of the elongate cavities defined by the scaffold plank 200, suchadvancement terminating when the end of the scaffold plank 200 isabutted against the main body 220 of the engagement portion 218 in theabove-described manner. It is contemplated that each end connector 202will be maintained in firm engagement to the scaffold plank 200 throughthe use of multiple fasteners such as screws 250. As seen in FIGS. 5 and6, one pair of screws 250 is advanced through respective ones of a pairof openings disposed within one side wall 208 of the scaffold plank 200and into respective ones of a complimentary pair of internally threadedapertures 252 disposed within one of the outer pair of fingers 230 ofthe end connector 202. A second pair of screws 250 is extended throughopenings in the remaining side wall 208 and into a complimentary pair ofinternally threaded apertures 252 disposed in the remaining finger 230of the outer pair. Since the openings in the side walls 208 of thescaffold plank 200 are disposed within the bottom surfaces of respectiveones of the slots 214, the heads of the screws 250 do not protrudebeyond the outermost surfaces of the upper and lower rails 210, 212 ofeach side wall 208, i.e., the heads of the screws 250 are effectivelycontained within respective ones of the slots 214. It is contemplatedthat the mechanical interlock between the end connectors 202 andscaffold plank 200 facilitated by the screws 250 may be supplemented bythe application of an adhesive to prescribed portions of each endconnector 202 prior to the advancement of the attachment fingers 230thereof into the interior of the scaffold plank 200. Additionally, thescrews 250 may be omitted in their entirety as a result of the use of anadhesive.

FIGS. 8 and 9 depict the manner in which a pair of scaffold planks 200which each include the end connectors 202 attached to each of theopposed ends thereof are interfaced to a horizontal support bar 254 of ascaffolding support frame 256. As seen in FIGS. 6, 8 and 9, the endconnector 202 is engaged to the support bar 254 such that the arms 226extend about the support bar 254. More particularly, the outer surfaceof the support bar 254 is abutted directly against the arcuate bodysurface 222 of the main body 220 and against the arms surfaces 228 ofthe arms 226. Advantageously, since the body surface 222 spans theentire length of the main body 220, the scaffold plank 200 is notsusceptible to rocking or tipping when weight or downward force isapplied to the longitudinal edges thereof.

Once one end connector 202 of one scaffold plank 200 is cooperativelyengaged to the support bar 254 in the above-described manner, one endconnector 202 of the remaining scaffold plank 200 is itselfcooperatively engaged to the same support bar 254. In this regard, thearms 226 of the end connector 202 of one scaffold plank 200 are nestedinto respective ones of the notches 224 of the corresponding endconnector 202 of the other scaffold plank 200 in the manner shown inFIG. 9. When the corresponding end connectors 202 of the scaffold planks200 are interfaced to the common support bar 254 as shown in FIG. 9, thecontours of the top surfaces of the arms 226 results in the distalportions thereof being recessed downwardly relative to the top surfacesof the main bodies 220 of the engagement portions 218 of thecorresponding end connectors 202.

As seen in FIG. 6, further in accordance with the present invention, itis contemplated that each end connector 202 of each scaffold plank 200may optionally be provided with a locking clip 258 which is preferablyfabricated from a resilient metallic material (e.g., steel) and securedto the main body 220 of the engagement portion 218 via one or morefasteners such as screws 260. It will be recognized that each endconnector 202 may be outfitted with one relatively large locking clip258, or multiple, smaller identically configured locking clips 258disposed in spaced relation to each other. The locking clip 258 is sizedand configured to frictionally engage the support bar 254 in the mannershown in FIG. 6, thus inhibiting the easy uplift of the end connector202 out of engagement to the support bar 254. Those of ordinary skill inthe art will recognize that the inclusion of the locking clip(s) 258 areoptional, and that alternative locking mechanisms may be included ineach end connector 202 to facilitate the secure connection thereof tothe scaffolding support frame 256.

Referring now to FIG. 10, further in accordance with the presentinvention, it is contemplated that the slots 214 included in the sidewalls 208 of each scaffold plank 200 may be used to accommodate edgeconnectors (not shown) which effectively maintain two or more scaffoldplanks 200 in side-by-side attachment to each other, i.e., thelongitudinal side wall 208 of one scaffold plank 200 is cooperativelyengaged to a corresponding side wall 200 of an adjacent scaffold plank200. In FIG. 10, three scaffold planks 200 are shown in suchside-by-side engagement, with the end connectors 202 of each set ofthree interconnected scaffold planks 200 themselves being cooperativelyengaged to a common horizontal support bar 254 of the scaffoldingsupport frame 256. As further shown in FIG. 10, it is also contemplatedthat a corner connector 260 may be used in conjunction with twointerconnected sets of scaffold planks 200, the corner connector 260being sized and configured to allow the interconnected sets of scaffoldplanks 200 to be effectively joined to each other, despite beingdisposed at a prescribed angular displacement relative to each other. Asshown in FIG. 10, the corner connector 260 includes an opposed pair ofside edges, each of which is formed to include an arcuate, generallyconcave engagement surface 262, a plurality of arms 264, and a pluralityof notches 266. The engagement surface 262, arms 264 and notches 266 ofeach side edge are structurally and functionally identical to the bodysurface 222, notches 224, and arms 226 of each end connector 202. Inthis regard, when the end connectors 202 of the interconnected scaffoldplanks 200 of one set are cooperatively engaged to the common supportbar 254, one side edge of the corner connector 260 may be cooperativelyengaged to the same support bar 254, with the arms 264 of the cornerconnector 260 being nested within respective ones of the notches 224 ofthe interconnected scaffold planks 200, and the arms 226 of theinterconnected scaffold planks 200 being nested within respective onesof the notches 266 of the corner connector 260.

The corner connector 260 is preferably fabricated from a plasticmaterial via an injection molding process, with the top surface of thecorner connector 260 also being provided with a roughened, non-sliptexture. As seen in FIG. 10, the corner connector 260 is sized to spanapproximately 30°, though those of ordinary skill in the art willrecognize that the corner connector 260 may be formed to span differingangular intervals. Additionally, multiple corner connectors 260 may becooperatively engaged to the scaffolding support frame 256 proximate toeach other so as to collectively define a span of more than 30°. Forexample, two corner connectors 260 as shown in FIG. 10 disposed inside-by-side relation to each other would span approximately 60°, withthree corner connectors 260 interlocked to the scaffolding support frame256 in side-by-side relation to each other spanning approximately 90°.Though the corner connector 260 shown in FIG. 10 is shown as being sizedto be interfaced to two sets of three interconnected scaffold planks200, the corner connector 260 may alternatively be sized and configuredto span between only two interconnected scaffold planks 200, or evenindividual scaffold planks 200 which are angularly displaced relative toeach other.

Referring now to FIGS. 11-16, there is shown a scaffold plank 300constructed in accordance with a fourth embodiment to the presentinvention. The scaffold plank 300 is preferably outfitted with a pair ofend connectors 302 which are cooperatively engaged to respective ones ofthe opposed ends of the scaffold plank 300. The structural andfunctional attributes of each end connector 302 (one of which is shownin FIGS. 13-15 as exploded from the scaffold plank 300) will bedescribed in more detail below.

As best seen in FIG. 16, the scaffold plank 300 is preferably a unitarystructure which defines a generally planar, sheet-like top wall 304 anda generally planar, sheet-like bottom wall 306. The top and bottom walls304, 306 extend in spaced relation to each other along respective onesof a generally parallel pair of planes. Extending perpendicularlybetween corresponding pairs of the longitudinal edges of the top andbottom walls 304, 306 is a spaced, generally parallel pair of side walls308. Though the inner surfaces of the side walls 308 are generallyplanar, the outer surfaces thereof each include an integral upper rail310 and an integral lower rail 312 extending longitudinally therealongin spaced, generally parallel relation to each other. The upper rails310 extend along respective ones of the opposed longitudinal sides ofthe top wall 304, and are each substantially flush with outer surface ofthe top wall 304. Similarly, the lower rails 312 extend along respectiveones of the opposed longitudinal sides of the bottom wall 306 and areeach substantially flush with the outer surface of the bottom wall 306.Each of the upper and lower rails 310, 312 preferably defined acontinuous slot or channel 314. The use of these channels 314 will bediscussed in more detail below.

The scaffold plank 300 further comprises a plurality of reinforcementwalls 316 which extend perpendicularly between the inner surfaces of thetop and bottom walls 304, 306. The reinforcement walls 316 extendlongitudinally along the length of the scaffold plank 300 in spaced,generally parallel relation to each other. Though the reinforcementwalls 316 are equidistantly spaced relative to each other, the spacingbetween the outermost pair of reinforcement walls 316 and respectiveones of the side walls 308 is slightly increased in comparison to thespacing between the reinforcement walls 316. As a result, an outer pairof cavities collectively defined by the top and bottom walls 304, 306,outermost pair of reinforcement walls 316, and side walls 308 each havea width which is slightly greater than that of multiple inner cavitieswhich are each collectively defined by the top and bottom walls 304, 306and an adjacent pair of the reinforcement walls 316. As seen in FIG. 16,the scaffold plank 300 is formed to include four (4) reinforcement walls316. As a result, the scaffold plank 300 includes three (3) innercavities and two (2) outer cavities which, as indicated above, are ofincreased width as compared to the inner cavities. However, those ofordinary skill in the art will recognize that the number ofreinforcement walls 316 included in the scaffold plank 300 as shown inFIG. 16 is exemplary only, in that greater or fewer reinforcement walls316 may be formed to extend between the top and bottom walls 304, 306.Also exemplary is the spacing between the reinforcement walls 316, inthat it is contemplated that the reinforcement walls 316 may beequidistantly spaced relative to each other and to the side walls 308,thus causing all of the cavities defined by the scaffold plank 300 to beof equal size.

In the scaffold plank 300, a pair of apertures 317 is disposed withineach of the side walls 308 and within each of the reinforcement walls316. In FIG. 16, only one aperture 317 of the pair included in each ofthe side walls 308 and each of the reinforcement walls 316 is shown, theremaining such aperture 317 being located in the same proximity to theopposite end of the scaffold plank 300 as the depicted aperture 317.Thus, the apertures 317 are provided in two sets, with the apertures 317of one set being disposed within the side walls 308 and reinforcementwalls 316 in equidistantly spaced relation to one end of the scaffoldplank 300, and the apertures 317 of the remaining set being disposedwithin the side walls 308 and reinforcement walls 316 in equidistantlyspaced relation to the remaining, opposite end of the scaffold plank300. As is apparent from FIG. 16, the apertures 317 of each set are alsopositioned in respective ones of the side and reinforcement walls 308,316 so as to extend in coaxial alignment with each other. The use ofeach coaxially aligned set of apertures 317 will be described in moredetail below.

It is contemplated that the scaffold plank 300 of the fourth embodimentwill be fabricated in its entirety from a non-metal material via anextrusion or injection molding process. Exemplary materials for thescaffold plank 300 include various types of plastics (e.g., glass-filledpolyethylene), fiber reinforced composites, or combinations thereof. Inthis regard, it is further contemplated that the extrusion processpreferably used to facilitate the formation of the scaffold plank 300may be carried out in a manner wherein various portions of the scaffoldplank 300 are fabricated from a fiber reinforced plastic or composite,with other portions simply being fabricated from a non-reinforcedplastic material. More particularly, depending on the level ofstructural integrity desired for the scaffold plank 300, one or more ofthe reinforcement walls 316 may be fabricated from a fiber reinforcedcomposite material, with the remainder of the scaffold plank 300 beingfabricated from a plastic material. As indicated above, the extrusionprocess preferably used to facilitate the formation of the scaffoldplank 300 may be completed such that the scaffold plank 300 is a unitarystructure, even if prescribed areas of the scaffold plank 200 arefabricated from differing non-metallic materials. As a furthervariation, the scaffold plank 300 may be fabricated entirely from anon-reinforced plastic material, with reinforcing sheets of a fiberreinforced composite material being applied to the outer surface of thetop wall 304 and/or the outer surface of the bottom wall 306 forpurposes of increasing the structural integrity/rigidity of the scaffoldplank 300.

In the scaffold plank 300, the outer surface of the top wall 304 ispreferably formed to have a roughened or textured feature to provide thescaffold plank 300 with non-slip characteristics. More particularly, itis contemplated that prescribed areas of the outer surface of the topwall 302 will be formed to include the roughened, textured feature, suchfeature being provided as three elongate textured strips 319 whichextend longitudinally along the outer surface of the top wall 304 inspaced, generally parallel relation to each other. In this regard, twoof the textured strips 319 extend along and in spaced relation torespective ones of the longitudinal sides or edges of the top wall 304,with the third, remaining textured strip 319 extending substantiallyintermediate the outer pair of textured strips 319. It is furthercontemplated that each of the three textured strips 319 will be formeddirectly in the outer surface of the top wall 304 during the process ofextruding the scaffold plank 300 by embedding three separate strips ofroughened fabric within the outer surface of the top wall 304immediately upon the same exiting the extrusion die. Subsequent to thecooling of the non-metal material used to form the scaffold plank 300,the removal or peeling of the fabric strips from the top wall 304 resultin the formation of the textured strips 319 therein. Thus, due to thetextured strips 319 constituting part of the top wall 304 as opposed toa separate substance applied thereto, such textured strips 319 are notsusceptible to chipping, flaking off or otherwise wearing away duringnormal use of the scaffold plank 300. Those or ordinary skill in the artwill recognize that the inclusion of three textured strips 319 as shownin FIG. 16 is exemplary only, in that the possible inclusion of greateror fewer textured strips 319 of greater or lesser width than that shownin FIG. 16 is contemplated to be within the spirit and scope of thepresent invention. Those of ordinary skill in the art will alsorecognize that the non-skid, roughened texture described above may alsobe included on the outer surface of the bottom wall 306.

As indicated above, the scaffold plank 300 of the fourth embodimentfurther includes a pair of end connectors 302 cooperatively engaged torespective ones of each of the opposed ends thereof. Each end connector302 includes an engagement portion 318 having a main body 320 whichdefines an arcuate, generally concave body surface 322. The body surface322 spans approximately ninety degrees. Formed within the main body 320is a spaced pair of notches 324, each of which defines an arcuate,concave apex. In addition to the main body 320, the engagement portion318 of the end connector 302 includes a spaced, identically configuredpair of arms 326 which are integrally connected to the main body 320.Each of the arms 326 defines an arcuate, generally concave arm surface328 which, like the body surface 322, also spans approximately ninetydegrees. The main body 320 and arms 326 are oriented relative to eachother such that one of the notches 324 is disposed between the arms 326,with the remaining notch 324 being disposed between one arm 326 and onelateral end of the main body 320. Importantly, the main body 320 andarms 326 are oriented relative to each other such that the arms surfaces328 of the arms 326 are continuous with the body surface 322 of the mainbody 320. Thus, the arms surfaces 328 and portions of the body surface322 collectively define engagement surfaces which span, in total,approximately 180°. As seen in FIG. 15, the side walls of the arm 326oriented between the notches 324 is continuous with the side walls ofsuch notches 324. One side wall of the remaining arm 326 is continuouswith the side wall of the notch 324 disposed between the arms 326. Asalso seen in FIG. 15, due to the shape of the engagement portion 318 ofeach end connector 302, the depth of the notch 324 located between thearms 326 appears to be greater than that of the remaining notch 324 dueto the side wall of the notch 324 between the arms 326 being continuouswith one side wall of each of the arms 326.

In addition to the engagement portion 318, each end connector 302includes a plurality of elongate, identically configured attachmentfingers 330 which protrude perpendicularly from the side of the mainbody 320 opposite that including the body surface 322 formed therein.The fingers 330 extend in spaced, generally parallel relation to eachother. As shown in FIGS. 13-15, five (5) attachment fingers 330 aredepicted as protruding from a common side of the main body 320. As isbest seen in FIGS. 13 and 14, the fingers 330 are sized and configuredto be advanceable into respective ones of the cavities defined by thescaffold plank 300. Disposed within each of the attachment figures 330is a coaxially aligned set of apertures 331. In this regard, theapertures 331 are positioned within each of the attachment figures 330such that the apertures 331 of each set, in addition to being coaxiallyaligned with each other, are also coaxially aligned with the apertures331 of each remaining set thereof. The advancement of the fingers 330into respective ones of the cavities is limited by the abutment of aperipheral portion of the surface of the main body 320 from which theattachment fingers 330 extend against corresponding lateral edges of thetop and bottom walls 304, 306 and side walls 308 of one end of thescaffold plank 300, in the manner shown in FIGS. 11 and 12. Importantly,when each end connector 302 is fully advanced into a respective end ofthe scaffold plank 300 in the aforementioned manner such that the mainbody 320 is abutted against the scaffold plank 300, all of the coaxiallyaligned apertures 331 of the end connector 302 will further be coaxiallyaligned with the apertures 317 of that set adjacent the end of thescaffold plank 300 into which the end connector 302 is inserted. Thus,upon the full insertion of the end connectors 302 into respective onesof the opposed ends of the scaffold plank 300, all of the apertures 331of each end connector 302, in addition to being coaxially aligned witheach other, are also coaxially aligned with one set of the apertures317. Though each end connector 302 is depicted as including five (5)attachment fingers 330 as described above, those of ordinary skill inthe art will recognize that end connectors 302 having greater or fewerattachment fingers 330 are contemplated to be within the spirit andscope of the present invention, the precise number of attachment fingers330 being dependent upon the corresponding number of cavities defined bythe scaffold plank 300.

It is contemplated that each end connector 302 will be fabricated from aplastic material via an injection molding process, with the attachmentfingers 330 being integrally connected to the main body 320 of theengagement portion 318. As best seen in FIG. 15, it is furthercontemplated that the structural integrity of each end connector 302 mayoptionally be increased through the inclusion of a reinforcement plate344 therein. The reinforcement plate 344 is preferably fabricated from ametal material (e.g., steel), and has a shape which is complimentary tothat of the main body 320, arms 326, and fingers 330. Though not shown,like the reinforcement plate 244 described above, the reinforcementplate 344 includes a plurality of reinforcement fingers which are sizedand configured to be advanceable into the interiors of respective onesof the attachment fingers 330. Additionally, the reinforcement plate 344includes a pair of arcuate reinforcement arms which are extensible intothe interiors of respective ones of the arms 326. Since the endconnector 302 is preferably fabricated via an injection molding process,it is contemplated that the reinforcement plate 344 will initially beincluded in the mold cavity, with the plastic material used to form theremainder of the end connector 302 being injected into the mold cavityin a manner effectively encapsulating the reinforcement plate 344 in themanner similar to that shown in FIG. 6 in relation to an end connector202.

As indicated above, the cooperative engagement of each end connector 302to a respective end of the scaffold plank 300 is facilitated by theadvancement of the fingers 330 of the end connector 302 into respectiveones of the elongate cavities defined by the scaffold plank 300, suchadvancement terminating when the end of the scaffold plank 300 isabutted against the main body 320 of the engagement portion 318 in theabove-described manner. It is contemplated that each end connector 302will be maintained in firm engagement to the scaffold plank 300 throughthe use of an elongate connector pin 350 which is shown in FIG. 17. Asshown, the pin 350 includes an enlarged, button-like head 352 which isformed at one end thereof. That end of the connector pin 350 oppositethe head 352 defines a juxtaposed pair of ear portions 354 which areseparated from each other by an elongate slot 356. Extending laterallyoutward from the distal end of each ear portion is an integral flangeportion. The pin 350 is fabricated from a plastic material of sufficientresiliency such that the ear portions 354 thereof may be selectivelyflexed inwardly into contact with each other.

To facilitate the attachment of each end connector 302 to the scaffoldplank 300, one pin 350 is advanced through the coaxially alignedapertures 331 of the end connector 302, and the coaxially alignedapertures 317 of the corresponding set of the scaffold plank 300. Theadvancement of the pin 350 through such coaxially aligned apertures 317,331 is continued until such time as the head 352 of the pin 350 isabutted against the outer surface of one of the side walls 308 of thescaffold plank 300. Advantageously, the pin 350 is sized such that oncethe abutment of the head 352 against one side wall 308 occurs, theflange portions of the ear portions 354 at the opposite end of the pin350 will protrude from the opposite, remaining side wall 308, and flexoutwardly into engagement with the outer surface of such side wall 308in a manner preventing the pin 350 from easily being removed from withinthe coaxially aligned apertures 317, 331. In the event that any endconnector 302 is to be separated from the scaffold plank 300, the flangeportions of the ear portions 354 of the corresponding pin 350 may besevered through the use of an appropriate cutting tool, thus allowingthe pin 350 to be removed from within the coaxially aligned apertures317, 331, and further allowing the end connector 302 to be separatedfrom the scaffold plank 300. Thus, the pins 350 are intended to besacrificial, with the re-attachment of the end connector 302 to thescaffold plank 300 being achieved by advancing a new pin 350 into thecoaxially aligned apertures 317, 331.

In the scaffold plank 300 including the end connectors 302, the mannerin which the such assembly is cooperatively engaged to a scaffoldingsupport frame occurs in the same manner described above in relation toFIGS. 8 and 9 regarding the engagement of the scaffold planks 200including the end connectors 202 to the scaffolding support frame 256.The channels 314 included in the side walls 308 of the scaffold plank300 may be used to accommodate edge connectors which effectivelymaintain two or more scaffold planks 300 in side-by-side attachment toeach other, i.e., the longitudinal side wall 308 of one scaffold plank300 is cooperatively engaged to a corresponding side wall 308 of anadjacent scaffold plank 300. Moreover, it is further contemplated that acorner connector similar to the corner connector 260 shown and describedabove in relation to FIG. 10 may be used in conjunction with thescaffold planks 300 including the end connectors 302 when such scaffoldplanks 300 are placed side-by-side.

Additional modifications and improvements of the present invention mayalso be apparent to those of ordinary skill in the art. In this respect,the planks formed in accordance with the present invention may be usedin applications other than for scaffolding. Thus, the particularcombination of parts described and illustrated herein is intended torepresent only certain embodiments of the present invention, and is notintended to serve as limitations of alternative devices within thespirit and scope of the invention.

1. A scaffold plank assembly for engagement to a scaffolding frame, thescaffold plank assembly comprising: an elongate, non-metal plankdefining opposed first and second ends; and a pair of end connectorsattached to respective ones of the opposed ends of the plank, each ofthe end connectors comprising: a main body defining an arcuate bodyengagement surface; an attachment portion which is integrally connectedto the main body and cooperatively engageable the plank; and at leasttwo arms attached to the main body, each of the arms defining an arcuatearm engagement surface, the body and arm engagement surfaces being sizedand configured to be cooperatively engageable to the scaffolding frame;the main body including at least two notches formed therein which eachhave a shape that is complementary to the arms, at least one of thenotches being disposed between the arms for matingly receiving one ofthe arms of a similar adjacent end connector therein; and a pair ofelongate pins, each of the pins being extensible through the attachmentportion of a respective one of the end connectors and through a portionof the plank adjacent one of the first and second ends thereof.
 2. Thescaffold plank assembly of claim 1 wherein each of the end connectors isfabricated from a non-metal material.
 3. The scaffold plank assembly ofclaim 2 wherein each of the end connectors further comprises an internalmetallic reinforcement plate which extends at least partially within themain body and arms thereof.
 4. The scaffold plank assembly of claim 1wherein each of the end connectors further comprises at least onelocking clip attached to the main body and frictionally engageable tothe scaffolding frame.
 5. The scaffold plank assembly of claim 1 whereinthe arcuate arm engagement surfaces are substantially continuous withthe body engagement surface in each of the end connectors.
 6. Thescaffold plank assembly of claim 1 wherein the attachment portioncomprises at least one elongate attachment finger which is extensibleinto an interior cavity defined by the plank and includes an aperturedisposed therein which is sized and configured to accommodate theadvancement of a respective one of the pins therethrough.
 7. Thescaffold plank assembly of claim 6 wherein the attachment portioncomprises a plurality of attachment fingers which extend in spaced,generally parallel relation to each other and are each extensible intothe interior cavity of the plank, each of the attachment fingersincluding an aperture disposed therein, the apertures of the attachmentfingers being generally coaxially aligned with each other and sized andconfigured to accommodate the advancement of a respective one of thepins therethrough.
 8. The scaffold plank assembly of claim 7 wherein theplank is fabricated from a plastic material.
 9. The scaffold plankassembly of claim 8 wherein the plank includes: an elongate, generallyplanar top wall defining inner and outer surfaces and opposed pairs oflongitudinal and lateral sides; an elongate, generally planar bottomwall defining inner and outer surfaces and opposed pairs of longitudinaland lateral sides; an opposed pair of sidewalls integrally connected tothe top and bottom walls and extending along respective pairs of thelongitudinal sides of the top and bottom walls in generally parallelrelation to each other; and a plurality of reinforcement wallsintegrally connected to and extending perpendicularly between the innersurfaces of the top and bottom walls and in spaced, generally parallelrelation to each other and to the side walls; the attachment fingers ofeach of the end connectors being extensible between respective adjacentpairs of the sidewalls and reinforcement walls of the plank.
 10. Thescaffold plank assembly of claim 9 wherein: each of the sidewalls andreinforcement walls of the plank includes a spaced pair aperturesdisposed therein, the apertures of the sidewalls and reinforcement wallsbeing segregated into two generally coaxially aligned sets which aredisposed in relative close proximity to respective ones of the opposedfirst and second ends of the plank; the apertures of each set arecoaxially alignable with the apertures of the attachment fingers ofrespective ones of the end connectors when the attachment fingers ofeach of the end connectors are extended between respective adjacentpairs of the sidewalls and reinforcement walls of the plank; and thecoaxially aligned apertures of the plank and each of the end connectorsare sized and configured to accommodate the advancement of a respectiveone of the pins therethrough.
 11. The scaffold plank assembly of claim 9wherein at least the outer surface of the top wall includes a texturedpattern integrally formed therein.
 12. An end connector for attachmentto an elongate plank defining opposed first and second ends, the endconnector being engageable to a scaffolding frame and comprising: a mainbody defining an arcuate body engagement surface; a plurality ofattachment fingers which are integrally connected to the main body andextend in spaced, generally parallel relation to each other, each of theattachment fingers being extensible into an interior cavity of the plankand including an aperture disposed therein, the apertures of theattachment fingers being generally coaxially aligned with each other;and at least two arms attached to the main body, each of the armsdefining an arcuate arm engagement surface, the body and arm engagementsurfaces being sized and configured to be cooperatively engageable tothe scaffolding frame; the main body including at least two notchesformed therein which each have a shape that is complementary to thearms, at least one of the notches being disposed between the arms formatingly receiving one of the arms of a similar adjacent end connectortherein.
 13. The end connector of claim 12 wherein the end connector isfabricated from a non-metal material.
 14. The end connector of claim 13wherein the end connector further comprises an internal metallicreinforcement plate which extends at least partially within the mainbody and arms thereof.
 15. The end connector of claim 12 wherein the endconnector further comprises at least one locking clip attached to themain body and frictionally engageable to the scaffolding frame.
 16. Theend connector of claim 12 wherein the arcuate arm engagement surfacesare substantially continuous with the body engagement surface.
 17. Ascaffold plank assembly for engagement to a scaffolding frame, thescaffold plank assembly comprising: an elongate, non-metal plankdefining opposed first and second ends; a pair of end connectorsattached to respective ones of the opposed ends of the plank, each ofthe end connectors comprising: a main body defining an arcuate bodyengagement surface; at least two attachment fingers which are integrallyconnected to the main body and extend in spaced, generally parallelrelation to each other, each of the attachment fingers being extensibleinto an interior cavity of the plank and including an aperture disposedtherein, the apertures of the attachment fingers being generallycoaxially aligned with each other; and at least two arms attached to themain body, each of the arms defining an arcuate arm engagement surfacewhich is substantially continuous with the body engagement surface, thebody and arm engagement surfaces being sized and configured to becooperatively engageable to the scaffolding frame; the main bodyincluding at least two notches formed therein which each have a shapethat is complementary to the arms, at least one of the notches beingdisposed between the arms for matingly receiving one of the arms of asimilar adjacent end connector therein; and a pair of elongate pins,each of the pins being extensible through the coaxially alignedapertures of a respective one of the end connectors and through aportion of the plank adjacent one of the first and second ends thereof.18. The scaffold plank assembly of claim 17 wherein the plank includes:an elongate, generally planar top wall defining inner and outer surfacesand opposed pairs of longitudinal and lateral sides; an elongate,generally planar bottom wall defining inner and outer surfaces andopposed pairs of longitudinal and lateral sides; an opposed pair ofsidewalls integrally connected to the top and bottom walls and extendingalong respective pairs of the longitudinal sides of the top and bottomwalls in generally parallel relation to each other; and a plurality ofreinforcement walls integrally connected to and extendingperpendicularly between the inner surfaces of the top and bottom wallsand in spaced, generally parallel relation to each other and to the sidewalls; the attachment fingers of each of the end connectors beingextensible between respective adjacent pairs of the sidewalls andreinforcement walls of the plank.
 19. The scaffold plank assembly ofclaim 18 wherein: each of the sidewalls and reinforcement walls of theplank includes a spaced pair apertures disposed therein, the aperturesof the sidewalls and reinforcement walls being segregated into twogenerally coaxially aligned sets which are disposed in relative closeproximity to respective ones of the opposed first and second ends of theplank; the apertures of each set are coaxially alignable with theapertures of the attachment fingers of respective ones of the endconnectors when the attachment fingers of each of the end connectors areextended between respective adjacent pairs of the sidewalls andreinforcement walls of the plank; and the coaxially aligned apertures ofthe plank and each of the end connectors are sized and configured toaccommodate the advancement of a respective one of the pinstherethrough.
 20. The scaffold plank assembly of claim 17 wherein atleast the outer surface of the top wall includes a textured patternintegrally formed therein.